The sunroof has stopped leaking and works well, so for now it's staying, even though it rattles a bit, which the old one didn't. I'll look at it sometime.
Another trait this car has had ever since I owned it has been a slow starter motor. Originally I put this down to the battery, then the battery clamps and earth lead connection, but recently it's been very slow again, to the point I thought it wasn't going to start the other day.
As a test I connected a lead straight to the solenoid trigger connection and touched it to the battery +ve. For 4 or 5 seconds it was very slow, but then sped up significantly. A few tries at this revealed similar results, or after a while it just being generally quicker.
This led me to believe the problem is the starter motor solenoid not throwing over fully so not delivering full current to the motor and yesterday I decided it was so bad I needed to have a look at the motor, or be left stranded.
Removing the starter motor is easy, but made awkward because the FDV is in the way.
Firstly, disconnect the battery -ve connection. This is important as the main +ve lead will be disconnected later and dangling about near the engine block, ready to short out, which could cause the battery to explode due to the current being drawn.
Next remove the intercooler to manifold duct and the turbo to intercooler duct for access.
Undo the clamps holding the 6mm pipes onto the FDV and remove the support bracket, then prise the FDV away from the engine a little to create space for the motor to pass by.
Undo the three starter motor bolts from the bell housing, then undo the +ve and trigger connections from the solenoid and with a bit of pursuasion the motor can be dropped down below the car.
Check the ring gear. This one is in fine fettle, but very dry, so put some grease into the teeth. I used molybdonem grease, but I suspect any will do.
The solenoid is a sealed unit, but after cleaning the motor body I stripped it off the motor to check the mechanism. The copper core inside the barrel looked like it may have been binding, so I cleaned it all up and sprayed it with WD40, including the contact push button inside.
I cleaned then lubed the drive gear shaft then lubed it and the end bearing, followed by more grease on the pinion, then rebuilt the unit and refitted it.
Tip: Fit the cables back to the solenoid before getting the motor back fully into position, it makes access easier.
Has it worked. YES! Today the starter motor was very quick indeed, probably the quickest I have heard on any XM of late. It's so quick, I'm now going to do the Mandarin car as well, as this one now makes that one appear slow.
For info. the starter is a Valeo D9R and replacement solenoids are avaialble for about £10, but servicing the motor probably means one won't be required and the motor, and probably the battery, will go for a long time after.